Shift Lever Shaft and Drive Shaft Housing

[Intermediate Mariner]

Hi,
This is my first thread. Any insight into my problem is much appreciated. I have searched the site for info on this.

I am working on a '62 35530 Evinrude 40 hp. I got it for $25... BUT I already had to replace lower unit as it was stored in the mud outside and was rusted.

The shift lever assembly was missing some parts so I removed the universal connector assembly and retainer ring. I am now at the shift lever that runs into the lower leg (drive shaft housing or exhaust tube).

Situation #1: The shift shaft is locked apparently in reverse. I can wiggle it and see it up in there from the lower leg but it appears locked.

Situation #2: The plastic shift lever saft bearing is torn (where it goes into the lower leg housing).

How do you get the lock to release. Someone said something about throttle and timing advance..??.. I cannot get it to release and have tried everything.

Also it appears I have to remove the lower leg to access this shift shaft to replace a couple of orings and plastic sleeves... or maybe even to get it unlocked...??. Additionally, the torn plastic sleeve has a little notch that slides into the housing. Will I have to remove the swivel assembly as well?

Any help much appreciated.

Thanks

 

[F_R]

Re: Shift Lever Shaft and Drive Shaft Housing

I assume the obvious is not the case here--that is the notched interlock bar is not keeping it from shifting. Right??

If the shift shaft is locked in the exhaust housing, big job. The powerhead has to come off. The little clevis lever inside the housing may be broken. It wouldn't be the first one to do that.

Another thing that sometimes happens is the shift shaft may be broken. To get the shift shaft and bushings/orings out, you have to remove the exhaust housing from the rubber mountings.

 

[Intermediate Mariner]

Re: Shift Lever Shaft and Drive Shaft Housing

Thanks for the input FR, much appreciated.

Correct, that's all been removed (lockout lever arm/pin and housing). I am down to the SHIFT LEVER SHAFT that goes into the exhaust tube/lower leg.

The Clevis Pin was removed from the shift rod assembly when I removed the lower unit.

There is a hole in the shift shaft UP INSIDE the inner exhaust housing and it looks like a bolt is in it that is keeping it from turning. It is all the way to the right (I believe in Reverse). It appears the shaft is locked in the housing.

I was hoping that there was just someything I was doing wrong.. it was shifting fine.

When you say remove power head to get to the shaft, is that basically taking the lower leg off as well as the lower motor cover and swivel assembly?... or am I just shooting to remove exhaust housing/lower leg?

Thanks a Million.

 

[Intermediate Mariner]

Re: Shift Lever Shaft and Drive Shaft Housing

Just to clarify I am talking about the shift shaft that goes into the top of the lower leg horizontally that the shift linkage hooks to.... not the shift rod vertical that runs down to the connection and then lower unit.

I have been unable to find ANYTHING about this in any service manuals. In the parts book it is called "shft lever shaft" part # 307449.

Thanks

 

[F_R]

Re: Shift Lever Shaft and Drive Shaft Housing

I know what you are talking about. Been there, done that, many times. But I don't know what you mean when you said clevis pin was removed when you removed the lower unit. Do you mean the upper shift rod came down with it??

In the center of the shift shaft is a clevis, with a bolt and nut through it, holding the upper shift rod. That clevis is what I am telling you is prone to breakage. When it breaks, it jams up, preventing the shift shaft from rotating. Something certainly is broken if the upper shift rod came down with the lower unit.

The "powerhead" is the complete gasoline engine attached to the top of the exhaust housing. You have to remove it to get to the clevis assembly.

If the shift shaft is broken and has to be removed from the exhaust housing, the exhaust housing must be removed from the lower covers. That is done by unbolting the several rubber mounts.

 

[Intermediate Mariner]

Re: Shift Lever Shaft and Drive Shaft Housing

Thanks so much FR for taking the time... I am sure you would rather BE boating than just talking about it!!

You are sure right Boss, I seen that the "clevis pin" was indeed like you said (I mistakenly thought it was the pin holding the upper and lower shift rod together- my mistake).

I see and understand the assembly now... but...
I can look up into the housing and nothing appears broken - but it is sure stuck! Something may be broke but it doesn't appear so but I cannot see all that great up in there. I do see that the clevis pin holds the "shift lever shaft clevis" into the shift rod and the 'shift lever shaft clevis' goes through the shift lever shaft hole in the center. Update: after looking in there again I see that the 'clevis shift shaft lever' nut is missing off that bolt that runs through the hole in the shift shaft... that nut is probably binding it up: and it looks like it just came off (the threads are still there just no nut).

The upper shift rod is not broken and still inside hanging down. I can grab it but it it locked.

It looks like I need to get to the clevis assembly. What is the easiest access to this? It looks like lower leg has to come off but that connects to the power head. Can I leave the exhaust housing alone and remove the powerhead? Will I be able to leave swivel transom assembly intact? Is removing the PH a one day/one man job? I keep going back to the exhaust housing because that shaft goes in at the top (near the PH) and is discusses in the exhaust housing section as opposed to the powerhead section. Someone told me 4 bolts to remove the powerhead, am I getting in over my head (I never never pulled a PH or an exhaust housing)?

Thanks FR,
Shawn

 

[Intermediate Mariner]

Re: Overhaul? Shift Lever Shaft and Drive Shaft Housing

Re: Overhaul? Shift Lever Shaft and Drive Shaft Housing

UPDATE:
I got the power head pulled - piece of cake (with the wife's help, of course)! I don't know why everyone always says to pull all these parts that are actually connected to the PH!

The shift shaft was bent AND the bolts were missing from clevis but I don't know how this happened. I hope that if I replace all the parts I'll be good.

Question: Should I go ahead and do an overhaul? Can I replace some rod or crank bearings or should I just leave it alone?

Thanks!!

 

[gayladanley]

Re: Shift Lever Shaft and Drive Shaft Housing

how do i get the drive shaft aligned back up and get the u joints past the gaskets, i guess/ it just isnt going in very easy at all